Vehicular outside mirror assembly

ABSTRACT

A rearview mirror for vehicles especially adapted for exterior vehicle use with electro-optic/electrochromic mirror units includes a reflective mirror element and a surrounding bezel having a raised edge or crown. The raised crown provides an appearance of narrowness and reduced bezel size. The bezel is preferably also thinner at the sides of the mirror than at the top or bottom and includes a rear retaining member which resiliently traps the mirror between a pair of resilient compressible seal members to form a continuous pocket at the edge of the mirror which is sealed against humidity, dirt, water, salt spray and other environmental effects commonly encountered by vehicles. Opposite polarity electrical connections for the electro-optic mirror unit are provided in different sizes or are mounted in different directions to prevent incorrect polarity connections to the vehicle electrical system.

BACKGROUND OF THE INVENTION

This invention relates to rearview mirrors for vehicles and, moreparticularly, to a mounting assembly for outside mirrors which protectsthe mirror unit and improves appearance while minimizing cost andsimplifying manufacturing operations.

In recent years, electro-optic rearview mirror assemblies for bothinterior and exterior vehicular applications have become popular. Thesemirrors include an electrically responsive material or medium whichdestructs incident light to reduce reflected light and glare. A typicalelectro-optic mirror unit includes a pair of glass or other opticallyclear panels, an electro-optic medium between the panels, electricalmeans for applying electric power to the electro-optic medium to varythe light transmittance through the medium, and a reflective layer forreflecting light through the medium which is incident on the mirror.Because of such construction, these units are larger, thicker andrequire more space than conventional mirrors. This is especially true atthe peripheral edges of the mirror to allow for electrical connectionsfrom the vehicle electrical system. Consequently, in the past, suchunits have been mounted on the vehicle in larger, thicker, bulkiermounting frames which are often unappealing in appearance.

In addition, these electro-optic mirror units are more sensitive thanconventional mirrors to environmental effects, especially at their edgeswhere high humidity and/or salt spray can cause corrosion or severelydegrade the reflective metal layers in the unit and/or short out anddisrupt electrical operation preventing proper dimming and/or glarereduction Such units are also electrical polarity sensitive. Hence,improper connection to reverse polarity electrical sources can damage ordestroy the operation of the units.

Additional problems encountered with such electro-optic rearview mirrorsinclude the destruction or damage due to vibration or breakage duringshipment, greater complexity in manufacturing operations and consequentgreater assembly cost, and difficulty in servicing such units includingremoval and replacement of the electro-optic units.

Prior known mounting frames for electro-optic rearview mirrors havefailed to address or solve these and related electro-optic rearviewmirror problems For example, Japanese Utility Model Patent Publication62-15052 discloses a mirror mounting assembly including a two-part rimwhich is fastened around the peripheral edge of the mirror unit andincorporates rubber or foam between the rim parts as a cushion forcompressive forces acting generally parallel to the plane of the mirrorunit. However, such mounting structure fails to address numerous otherproblems as described above including protection from numerous types ofenvironmental effects, prevention of improper polarity connections tothe vehicle electrical system, accommodation of mirror serviceabilitysuch as mirror removal and replacement, and minimization of bulk andsize for improved appearance.

The present invention was developed in recognition of and as a solutionfor these and other problems

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a rearview mirror assemblyfor vehicles, especially for the exterior of vehicles, which is uniquelyadapted to receive electro-optic/electrochromic mirror units, provideeffective protection against environmental effects and vibration bothduring shipment and after installation on the vehicle, as well asprotection against incorrect polarity connections to the vehicleelectrical system. In addition, the assembly has an improvedsize-minimizing appearance which creates the impression of smalldimensions. Further, the assembly uniquely accommodates serviceabilityby allowing ease in removal and replacement of the electro-optic unitswith minimal difficulty and cost.

In one aspect, the invention is a rearview mirror assembly for vehiclescomprising a rearview mirror having a mirror element with front and rearsurfaces and peripheral top, bottom and opposing end edges as well as areflective coating on one of the front or rear surfaces. A bezel whichsurrounds and holds the mirror has a rim engaging the front surface ofthe mirror, a peripheral side adjacent the peripheral edges of themirror, and means for holding the mirror within the bezel. Mountingmeans are provided for connection to a mirror support. The bezel rimincludes a crown extending around the entire bezel and an inner edgeengaging the front of the mirror. The crown is spaced inwardly towardthe inner edge from the peripheral side and divides the rim into aninner surface sloping from the crown to the inner edge and a lateralsurface sloping from the crown toward the peripheral side of the bezel.Thus, when viewed from the front of the mirror at an angle, such as theangle at which the mirror is viewed by the driver or those outside thevehicle, the bezel appears thinner than its full width due to lightaccenting the crown and deemphasizing the inner rim surface.

In other aspects, the invention includes a bezel having a rim with afirst width along the front mirror surface adjacent the top and bottomedges a second, smaller width along the opposing end edges of the mirrorwhich is less than the first width. When viewed at an angle from thefront and adjacent one end, such bezel rim appears smaller at the endedges of the mirror thereby deemphasizing the size and appearance of thebezel on the assembly. This bezel having differential width rim portionsat the sides versus the top and bottom of the mirror may be combinedwith the crown which extends around the entire bezel for deemphasizingthe inner rim surface.

In yet another aspect of the invention, the bezel which surrounds themirror has a rim engaging the front surface of the mirror and aperipheral side adjacent the peripheral edge surface of the mirror. Aretaining member adjacent the rear surface of the mirror engages thebezel to hold the mirror within the bezel. Cooperating means on thebezel and retaining member hold the retaining member and bezel togetherwhile mounting means are provided for connection to a mirror support.Seal means within the bezel and retaining member seal the peripheraledge of the mirror. The seal means include a first resilientcompressible seal member extending around the entirety of the mirroradjacent the mirror periphery and intermediate the rim inner surface andthe mirror front surface. A second resilient compressible seal memberextends around the entirety of the mirror adjacent the mirror peripheryand intermediate the retaining member and the mirror rear surface. Theseseal members and the imperforate peripheral side of the bezel define agenerally open pocket adjacent the peripheral mirror edge which issealed environmentally to protect the peripheral mirror edge includingthe reflective coating against environmental effects such as water,dirt, salt spray, humidity, corrosion and the like. Further, the firstseal resiliently urges the mirror rearwardly against the second sealmember to ensure a secure environmental seal and hold the mirror tightlyand cushion the mirror against vibration and shock.

In other aspects of the invention, the rearview mirror assemblyaccommodates an electro-optic mirror unit including a pair of electricalconnections to the electro-optic mirror, a bezel surrounding and holdingthe mirror unit, and mounting means for connection to a mirror support.The bezel includes a support for mounting the pair of electricalconnections for connection to a vehicle electrical system. The pair ofelectrical connections has opposite polarities and includes means forpreventing incorrect polarity connections from the vehicle electricalsystem. In one form, the means for preventing incorrect polarityconnections include mounting the electrical connections to extend indifferent directions so as to mate with corresponding vehicleconnections of the same polarity on electrical leads having differentlengths. In another form, the pair of electrical connections each has adifferent size/dimension adapted to mate with a correspondingly sizedconnection of the same polarity from the vehicle electrical system.

The present invention, therefore, provides a mounting structureespecially adapted to receive electro-optic/electrochromic mirror unitswhich have larger sizes, thicknesses and greater space needs at theiredges for electrical connections. The assembly provides an improvedappearance which minimizes the appearance of the mounting bezel andcreates the impression of small dimensions, especially when viewed at anangle from either inside or outside the vehicle on which it is mounted.Further, the invention provides improved protection forelectro-optic/electrochromic units, especially when mounted on theoutside of a vehicle, against the effects of the environment such asdirt, humidity, corrosion, salt spray, water and the like which canphysically degrade the electro-optic units as well as short out ordisrupt electrical operation thereof. The invention also protects theelectro-optic mirrors from vibration and shock both during shipment andafter installation on a vehicle. Also, the invention accommodatesserviceability by allowing easier removal and replacement of theelectro-optic mirror units thereby minimizing costs. In addition,destruction and damage of the electro-optic mirror units is avoidedthrough inclusion of electrical connections which prevent incorrectpolarity connections to the vehicle electrical system.

These and other objects, advantages, purposes and features of theinvention will become more apparent from a study of the followingdescription taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation of a rearview mirror assembly incorporatingthe present invention;

FIG. 2 is a perspective view of the mirror assembly of FIG. 1 withportions of the mirror element broken away;

FIG. 3 is a top plan view of the mirror assembly of FIGS. 1 and 2;

FIG. 4 is an exploded, perspective view of the mirror assembly of FIGS.1-3 illustrating a portion of the separate components of the assembly;

FIG. 4A is an exploded, perspective view similar to FIG. 4 showing theremaining separate components of the mirror assembly of FIGS. 1-3;

FIG. 5 is a fragmentary sectional view of the mirror assembly takenalong Plane V--V of FIG. 1;

FIG. 5A is a fragmentary, sectional view of the mirror assembly of FIGS.1-5 similar to FIG. 5 but illustrating the assembly process prior tocompletion;

FIG. 6 is a sectional view of the bezel of the mirror assembly takenalong Plane VI--VI of FIG. 1;

FIG. 7 is a fragmentary, sectional view of the inner edge of the frontrim of the bezel of the mirror assembly showing area VII in FIG. 5;

FIG. 8 is a fragmentary, perspective view of a portion of the bezelmember of the present mirror assembly;

FIG. 9 is a rear perspective view of the retaining member of the presentmirror assembly adapted to mate with the bezel member to hold the mirrorunit therein;

FIG. 10 is a front elevation of the retaining member shown in FIG. 9;

FIG. 11 is a sectional view of the retaining member taken along PlaneXI--XI of FIG. 10;

FIG. 12 is a sectional view of the electrical connection mountingportion of the retaining member taken along Plane XII--XII of FIG. 10;

FIG. 13 is a fragmentary, perspective view of the electrical connectionmounting area of the retaining member;

FIG. 14 is a fragmentary, sectional view of an alternate form of therearview mirror assembly of the present invention including anelectrical heating pad/element on the rear surface of the mirror unit;and

FIG. 15 is a rear perspective view of an alternate form of the retainingmember adapted to be used in conjunction with the bezel of the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in greater detail, FIGS. 1-13 illustrate afirst embodiment 10 of an exterior rearview mirror assembly for vehiclesincorporating the present invention. The mirror assembly 10 includes abezel 12 surrounding, engaging and holding the peripheral edge of arearview mirror unit 14 preferably of the electro-optic type. Mirrorunit 14 includes electrical connections adapted to be joined to thevehicle electrical system to provide a small voltage source ofelectrical power. Alternately, a heating pad or element 152 as describedbelow may be applied to the rear surface of the mirror unit 14 todefrost/de-ice the mirror assembly when used in colder climates.

With reference to FIGS. 1, 2, 4 and 5, the electro-optic mirror unit 14is preferably of the type having a first or front, optically clear,mirror element 16 and a second or rear, optically clear, mirror element18. Element 18 is spaced slightly rearwardly from front element 16 todefine a gap or space 20 for receiving an electro-optic medium 22 asexplained below. Preferably, front and rear elements 16, 18 are eachformed from a generally planar sheet of conventional soda lime windowglass. Alternately, elements 16, 18 may be resinous, polymeric sheets tohelp prevent fragment scattering and lacerative injuries if broken andalso to reduce weight Elements 16, 18 are cut to the shape of aconventional outside vehicular mirror as shown in FIG. 1, although othershapes are certainly possible. Space 20 is formed between the parallelrear surface 24 of front glass element 16 and the forward facing frontsurface 26 of rear glass element 18. Preferably, each of the front andrear surfaces 24, 26 is coated with a layer of indium-tin oxide (ITO)which is substantially transparent to incident visible light yet issufficiently electrically conductive to enable application of anelectric field or voltage across space 20 between the ITO layers.

As shown in FIG. 5, elements 16 and 18 are preferably offset verticallyfrom one another such that the lower edge of front element 16 projectsbelow the lower edge of rear element 18 along the bottom of the mirrorunit while the upper edge of element 18 projects above the upper edge ofelement 16 along the top of the mirror unit. The downwardly and upwardlyprojecting edges of the elements 16, 18 receive elongated, terminals ormetal clips 28 which are preferably formed from bent copper sheet andare crimped around the extending lower and upper edges of theseelements. Consequently, the ITO coated surface of each element 16, 18 isfirmly contacted by a separate one of the cups 28. Wire leads 30 aresoldered to clips 28 (FIGS. 4 and 5) and extend rearwardly from theelectro-optical mirror unit 14 for connection to spay-type electricalconnectors 32 for ultimate connection to the vehicle electrical system.Other types of electrical connections from the vehicle electrical systemdifferent from cups 28 may be joined to the mirror unit as described inco-pending, commonly assigned U.S. Pat. application Ser. No. 454,398,filed Dec. 21, 1989, now U.S. Pat. No. 5,066,112, entitled "PERIMETERCOATED, ELECTRO-OPTIC MIRROR", the disclosure of which is herebyincorporated by reference herein.

The rear surface of rear glass element 18 is preferably coated with areflective layer 34 of metallic material such as aluminum, or acombination of silver and copper as is conventionally known. Such layerprovides a highly specular surface which reflects approximately 80% to90% of the light incident thereon through front and rear glass elements16, 18 and electro-optic medium 22 in space 20. In order to preventscattering of glass fragments from the rear glass element 18 in theevent of breakage or damage during a collision in the vehicle, a layer36 of tape or a plastisol-type plastic adhesive, or an adhesive coatedmetal foil, typically about 0.1 mm thick, is applied to the rear surfaceof reflective coating 34. Anti-scattering layer 36 may be opaque,translucent or transparent since it is behind reflective coating 34 andneed not transmit or reflect any light. In addition, the front surfaceof front element 16 may be scatter and antilacerative protected with aresinous, polymeric or other coated or applied layer 38 o its first orfront surface. Layer 38 also preferably reduces ultraviolet lightradiation into the assembly to prolong the operative life of theelectro-optic medium 22. Alternately, or in combination with layer 38,other scatter preventing means such as a laminate first element, andadditional UV protection may be included as described in co-pending,commonly assigned, U.S. Pat. applications Ser. No. 496,271, filed Mar.20, 1990, now U.S. Pat. No. 5,073,012, entitled "ANTI-SCATTER,ULTRAVIOLET PROTECTED, ANTI-MISTING, ELECTRO-OPTIC ASSEMBLIES", and Ser.No. 464,888, filed Jan. 16, 1990, now U.S. Pat. No. 5,115,346, entitled"ANTI-SCATTER, ULTRAVIOLET PROTECTED, ANTI-MISTING, ELECTRO-OPTICALREARVIEW MIRROR", the disclosures of which are hereby incorporated byreference herein.

In order to confine and retain the electro-optic medium 22 in gap 20, aperipheral seal 40, preferably formed from an epoxy material whichadheres well to the ITO coatings on surfaces 24, 26 on elements 16, 18is applied adjacent the periphery of the glass elements. A suitableepoxy sealing material is EPON 828 (T.M.) from Shell Chemical Company ofHouston, Tex., cured by a polyamide based curing agent such as V-40(T.M.) from Miller Stevenson Company of Danbury, Conn. The epoxy ispreferably silk screened onto the inner surface of front glass element16, or rear glass element 18, or both glass elements. The correspondingglass element is then placed face to face with the still, tacky epoxy.Seal 40 is then fully cured, typically by placing the assembly in anoven at 110° C. for three hours. Gap 20 can be filled by a variety ofmeans such as a simple injection of electro-optically active liquid,semi-liquid or gel material using a syringe or by vacuum back fillingusing a technique well established for manufacture of liquid crystaldevices.

Typically, glass elements 16, 18 will each be 2 mm in thickness whileITO coatings 24, 26 will have a typical thickness of 1,500 angstroms.Reflective coating 34 may have a thickness within the range of betweenabout 500 and 1,000 angstroms. Various types of electro-optic media 22may be inserted in gap 20. For example, a suitable liquid crystalmaterial in which molecules are oriented to block the passage of lighttherethrough when an electric field is applied is a guest host die suchas D5 (T.M.) produced by BDH Co. of Dorset, England, dissolved in n-typenematic liquid crystal such as n-(p-methoxybenzilidene)-p'-butylaniline.For such material, cell gap 20 is typically 8 to 12 microns. Forelectrochemichromic mirrors, gap 20 may contain a liquid, thickenedliquid, gel or semi-solid material such as formulations described inU.S. Pat. No. 3,506,229 to Schoot. In electrochromic mirrors, a materialsuch as poly-AMPS (T.M.) available from Lubrizol Corp. of Wickliffe,Ohio may be used. Also, a liquid, thickened liquid, gel or semi-solidmaterial may be used as is conventionally known. Cell gap or space 20 istypically 50 to 150 microns in these electrochromic orelectrochemichromic devices. With the latter materials, application ofan electric field will cause the medium 22 to color to successivelydarker colors or shades as larger voltages are applied. When voltage isturned off or reversed, the coloring is bleached allowing fulltransmittance of light and, hence, full reflectivity of reflective layer34.

With reference to FIGS. 1-6, bezel 12 includes a one piece bezel frame50 preferably molded from "Noryl" (T.M.) poly-phenyl-oxide availablefrom G.E. Plastics of Pittsfield, Mass., which extends around the entireperiphery of the rearview mirror unit 14 and includes a front rimportion 52 extending inwardly toward the center of the mirror unit and aperipheral side portion 54 which extends rearwardly from rim 52 alongand beyond the periphery of mirror unit 14. Rim 52 includes a recessedinterior surface 56 facing the front surface of the mirror unit anddefining a channel extending continuously around the undersurface of therim as shown in FIG. 5. Channel surface 56 receives a bead 74 of sealantto close off, seal and protect the edge of mirror unit 14 as describedmore fully below. The outer surface of the rim 52 includes a raisedridge or crown 58 intermediate the inner edge 60 and the outerperipheral surface 62. Crown 58 extends around the entire mirror unit onrim 52 and helps provide an aesthetically pleasing appearance minimizingthe size of the mirror assembly as explained below. Crown 58 alsodivides rim 52 into a generally planar, inner surface 64 extendingbetween the crown and inner edge 60 and a generally planar, lateralsurface 66 extending between the crown and the outer peripheral surface62. Peripheral side 54 tapers inwardly toward the rear portion 67 andincludes a series of spaced stops or shoulders 68 on its inner surfaceas are best seen in FIGS. 1-6 and 8. Inner edge 60 of rim 52 includes aplanar undersurface 61 (FIG. 7) which contacts the front surface ofmirror unit 14 to help provide an environmental seal between the mirrorunit and rim as well as to avoid the necessity of molding a knife edgeon the rim.

Stop shoulders 68 are spaced rearwardly from the rear surface of mirrorunit 14 to allow sufficient room for installation and retention of aretaining plate member 80 (FIGS. 8-12) which holds the mirror unit inplace against planar surface 61 and sealant 74 on the underside of rim52. The shoulders 68 are spaced substantially equally around the bezelto firmly hold the retaining plate 80 in all locations. Each stopshoulder 68 includes an abutment face 70 which extends generallyperpendicular to the inner surface of peripheral side 54 and generallyparallel to planar surface 61 on rim 52 and to the rear surface ofmirror unit 14 when placed in the bezel. In addition, each stop shoulder68 includes an inclined, ramp surface 72 which extends from the insidesurface of rear portion 67 of peripheral side 54 at an inwardlyextending angle to the top of abutment surface 70. When retaining member80 is forced inwardly toward the rear surface of mirror unit 14 duringassembly of the mirror, as described below, the outer edge of retainingmember 80 will force ramp surfaces 72 outwardly and flex the peripheralside of bezel 12 to allow insertion of the retaining plate behind stopsurfaces 70.

As is best seen in FIGS. 2, 4A, 5 and 9-12, retaining plate member 80 isadapted for use with bezel frame 50 to retain the mirror unit 14 withinthe bezel 12. Retaining member 80 is a one-piece plate 82 preferablymolded from Noryl (T.M.) poly-phenyl-oxide having an exterior outlinegenerally corresponding to the shape of the mirror unit 14 as is shownin FIG. 10. Plate 82 includes a central aperture 84 which alsocorresponds in shape to the exterior shape of mirror unit 14 but is of areduced dimension in comparison. Central aperture 84 is outlined by araised rib 86 which extends continuously around the entire inner edge ofthe aperture for rigidity and stiffness. At four locations on the topand bottom of plate 82 on rib 86 are formed locating projections 88which are adapted to mate with corresponding apertures 104 in mountingplate 100 to be described hereinafter. On the inner edge of plate 82extending inwardly into the opening provided by central aperture 84 andintegrally joined with rib 86 is a support pad 90 adapted to receive andmount electrical connectors 32 on electrical leads 30 (FIG. 4A). Oncethe retaining plate 80 is mounted within bezel frame 50 behind shoulderstops 68 as shown in FIG. 5, the electrical leads 30 must extend throughthe assembly such that the connectors 32 can be mounted on pad 90. Forthis purpose, a pair of semicircular recesses 92 are provided at theupper and lower corners of the inside edge of plate 82 to allow passageof wires 30 for attachment of connectors 32 on pad 90.

As is best seen in FIGS. 9-13, support pad 90 includes a series ofprojections 94, 96 adapted to receive and retain electrical connectors32 attached to wire leads 30. The projections include a pair of spacedmounting posts 94 and a pair of upstanding retaining clips 96 alignedwith one another and spaced adjacent and on either side of each post 94.Each electrical connector 32 has a circular aperture therein which isadapted to be received over post 94. As the electrical connector ispressed down over a post 94, the inclined top surfaces 97 of fasteningclips 96 are engaged thereby camming clips 96 slightly apart to allowthe connector to slide therepast. Since each of the clips includes anoverhanging lip 98 (FIG. 12), the generally planar electrical connectorslides past these lips which then snap back over top the connector andhold it securely against the planar surface of pad 90. Alternately,connectors 32 could be secured to support 90 with Tinnerman connectors,heat staked or otherwise securely fastened.

As is best seen in FIG. 4A, retaining plate member 80 is adapted to beused with mounting plate 100 which is preferably molded from plasticsuch a GTX 910 (T.M.) poly-phenyl-oxide available from G.E. Plastics ofPittsfield, Mass., and includes an outer circumference corresponding inshape to the edge of central aperture 84 in plate 82. Mounting plate 100includes an offset, outwardly projecting rim 102 which is continuousexcept for four apertures 104 adapted to receive locating projections 88to properly position plate 100 within aperture 84 on plate 82. Inaddition, rim 102 includes a generally rectangular cutout 106 whichreceives mounting pad 90 for the electrical connectors when plates 82,100 are fitted together. As will be seen from FIG. 4A, the rear surfaceof mounting plate 100 includes a series of mounting projections 108adapted to mate with a control unit or motor unit for supporting themirror assembly on a vehicle and allowing its position to be controlledremotely from within the vehicle interior. These mounting projections108 are of conventional form and may be chosen to mate with any ofseveral different types of electrical control motors or manuallyoperated control wires. Thus, mirror assembly 10 may be assembled andshipped to another site where it can be quickly and easily adhered, witha suitable adhesive, to mounting plate 100 which is already assembled tothe exterior mirror assembly.

Alternately, in place of the two-part retaining plate 80/mounting plate100 combination, a one-piece generally planar retaining member of plate110 may be substituted. As shown in FIG. 15, plate 110 is a generallyplanar, one-piece member also preferably molded from Noryl (T.M.)poly-phenyl-oxide on which are formed projections such as projections94, 96 in order to hold electrical connectors 32, 32' thereon. Inaddition, notches 112 are formed in the upper and lower inside cornersof plate 110 to allow passage of the electrical wires 30 as describedabove. Further, mounting projections 114 allow connection of the plate,and thus the entire mirror assembly 10 to an electrical control unit ormanually operated control mounted on the vehicle. Plate 110 allows theentire mirror assembly to be secured to the control and mirror mount atone time. Therefore, the two differing forms 80/100 and 110 of theretaining plate allow flexibility in manufacturing options.

With reference to FIGS. 4, 4A, 5 and 5A, assembly of the bezel with themirror unit will now be understood. Bezel frame 50 is supportedhorizontally on a support surface with rear portions 67 extendingupwardly and the support surface engaging crown 58. A continuous bead ofresilient, compressible sealant material is laid in channel 56 on theinside surface of rim 52. Sealant bead 74 has a sufficient size/diameterto extend rearwardly of the planar surface 61 on the inner edge 60 ofrim 52 (FIG. 5A). Preferably, the sealant bead is of a type which willflow on surfaces and, when applied, is an uncured material such as asilicone plastic adhesive sold under No. 739 by Dow Chemical Corporationof Midland, Mich. The uncured bead of silicone sealant is allowed tocure in the air at room temperature until it is "tack-free", i.e., nottacky or sticky on its surface. Alternately, other types of siliconesealants or butyl, EPDM or molded neoprene sealants may be used withsimilar successful results.

Once bead 74 is in a tack-free condition, rear portions 67 of theperipheral side 54 of bezel frame 50 is bent slightly outwardly andmirror unit 14 is placed inside frame 50 such that the front surface ofthe mirror unit 14 engages bead 74 (FIG. 5A). Frame 50 is of sufficientsize to provide a space between the outer peripheral edges of elements16, 18 (FIGS. 5 and 5A). Wire leads 30 are bent to extend substantiallyparallel to the peripheral sides 54 and a second bead 76 of the samesealant material, preferably Dow silicone plastic adhesive No. 739, isapplied to the rear surface of mirror unit 14 adjacent the peripheraledge of rear element 18 as shown in FIG. 5A. Thereafter, retaining platemember 80, which may include a slanted edge surface 83 to facilitatemovement over inclined ramp surface 72, is placed inside bezel frame 50and pressed against the ramp surfaces 72 of stop shoulders 68 downwardlytoward the mirror unit 14. Such pressure cams rear portion 67 of bezelframe 50 outwardly until retaining plate member 82 snaps in place behindthe abutment surfaces 70 while also engaging sealant bead 76 on the rearmirror unit surface. Rear portion 67 of bezel frame 50 is sufficientlyresilient and flexible to allow such insertion. Pressure of theretaining plate 80 against the sealant bead 76 compresses the sealantinto a thinner layer such that it flows both inwardly and outwardly ofthe peripheral edge of the rear mirror unit surface and slightly intothe space adjacent the peripheral edge of the mirror unit as shown inFIG. 5. At the same time, such pressure forces the front surface ofmirror unit 14 into engagement with planar surface 61 at the inner edge60 of rim 52 while compressing sealant bead 74 within channel 56 asshown in FIG. 5. Hence, with retaining plate member 80 held in place byabutment surfaces 70, mirror unit 14 is held securely between thecompressed beads of sealant 74, 76 and tightly against the planarsurface 61. The resilient, adhesive sealant beads thus seal the edgearea of the mirror unit within the imperforate peripheral side of bezelframe 50 forming a continuous sealed, pocket around the mirror unit edgewhich is protected from the effects of the environment such as moisture,dirt, salt spray, humidity and the like. Since the metallic reflectivelayer 34 is highly sensitive to such environmental effects, the sealantbeads 74, 76 protect that reflective layer as well as the electricalclip and wire connections 28, 30 at the edge of the mirror unit. Inaddition, the resilient sealant material helps to absorb shock andvibration both during shipment of the mirror assembly to itsinstallation point as well as after assembly when mounted on a vehiclethereby helping to protect the electro-optic mirror unit.

As will also be understood, use of sealant 74, which is air cured to anon-tacky state prior to assembly, allows mirror unit 14 to bedisassembled from bezel frame 50 without leaving a residue of sealant onthe mirror. Likewise, if mirror assembly 10 must be repaired aftermanufacture, it can be disassembled to allow replacement or repair ofmirror unit 14. This helps reduce costs by allowing re-use of variousparts without discarding an entire assembly simply because one part isdamaged or inoperative.

When installed on mirror unit 14, bezel assembly 12 also provides uniqueappearance advantages over prior known bezels, especially forelectro-optic mirror units. As is best seen in FIG. 1, the generallyvertically extending side portions 52a, 52b of bezel rim 52 are thinnerand narrower than the top and bottom portions 52c, 52d of the bezel rim.Since the width of rim 52 need not be as great at the sides where themirror elements 16, 18 are aligned with one another (see FIG. 4) whereasthose same elements are offset from one another at the top and bottomsof the mirror unit as shown in FIGS. 4, 5 and 5A. In addition, thecontinuous crown 58 which extends around bezel rim 52 helps provide athinner, narrower appearance for the bezel on the mirror unit,especially when viewed at an angle from the front surface as shown inFIG. 2. Incident light strikes, accents and highlights the crown surfaceand de-emphasizes the inclined inner and lateral surfaces 64, 66providing the appearance of a smaller bezel when viewed at such anangle. The position of the crown 58 causes the length projection of theinner surface 64 of the bezel rim (dimension A in FIG. 5) to be greaterthan the projection of the lateral surface 66 (dimension B) at allpositions around the bezel as shown in FIGS. 5 and 6. Thus, withreference to those figures, dimension A is greater than dimension Bwhile dimension C is greater than dimension D. However, along the sidesof the mirror, the ratio of C:D is greater than A:B as shown in FIGS. 5and 6. Also, while the overall width of the bezel is sufficient toaccept and cover the necessarily larger sized electro-optic mirror unitedge including electrical connections, the appearance from the front isof a thinner bezel providing a more appealing appearance to theconsumer. In addition, the height of crown 58 projects as little aspossible beyond the front surface of the mirror unit Accordingly,together, thinner sides 52d, 52b and positioning of the raised ridge orcrown 58 minimize the size of the bezel 12 in appearance.

After the retaining plate 80 or 110 is positioned behind stop members68, with wire leads 30 extending through notches 92 or 112, electricalconnectors 32 may be snapped in place over mounting post 94 betweenclips 96. As shown in FIGS. 4A, 13 and 15, however, electricalconnectors 32 which are of opposite polarity in order to allow properoperation of the electro-optic mirror unit 14, are positioned inopposite directions from one another on support pad 90 or retainingplate 110. The opposite positioning of the electrical connector isadapted to prevent incorrect polarity connections from the vehicleelectrical system. For example, wire leads from the electrical system ofthe vehicle are preferably made of different lengths so that a shortlead having a corresponding electrical connectors to spay connector 32may only be attached to one or the other of the electrical connectors 32while a longer wire lead from the vehicle electrical system may bereversed in direction and attached to the other connector. Hence,because of the physical dimensions of the leads from the vehicle system,and the opposite positioning of connectors 32, installation withincorrect polarity connections to the mirror unit 14 are avoided.

Alternately, as shown in FIG. 15, electrical connectors 32 may be madeof different sizes or dimensions so that correspondingly sizedconnectors from the vehicle electrical system can only be attached tothe appropriately matched electrical connector on the rear of the mirrorassembly. Again, incorrect polarity connections, and thus damage ordestruction of the polarity sensitive mirror unit 14, are avoided.

As shown in FIGS. 4A and 14, an alternate mirror assembly 150 mayincorporate one of various types of heating elements or pads 152 appliedto the rear surface of mirror unit 14. In assembly 150, where likenumerals indicate like parts to those described above, mirror unit 14 isassembled within bezel 12 using sealant beads 74, 76 and rear retainingplate member 80 as in mirror assembly 10. However, prior to suchassembly, a thin sheet of aluminum foil 151 followed by a heating padsuch as that shown at 152 in FIG. 4A are applied to the rear surface ofthe mirror unit by silicone or other appropriate adhesives. Foil sheet151 helps conduct heat uniformly over the entire mirror unit from pad152. Also, sheet 151 eliminates the need for anti-scatter layer 36 sinceit is adhered tighly to rear element 18 and itself produces a fragmentretention, anti-scatter function in the event mirror unit 14 isimpacted. Heater pad 152 preferably is a positive temperaturecoefficient pad available from ITW Chronomatic of Chicago, Ill. underModel No. D9968 and is die cut to the shape of the mirror unit or to arectangular or trapezoidal shape. Sheet 151 of aluminum foil preferablyhas a thickness of approximately 0.017 inches and is supplied by 3MCorporation of Minneapolis, Minn. under Part No. M6169. The thicknessmay be varied depending on desired heating speed, i.e. thinner forincreased heating speed. Electrical leads 153 154 are secured to heaterpad 152 and extended along the back of the mirror unit through thesealant bead 76 and out through notches 92 or 112 along with electricalleads 30 from mirror unit 14. Since the voltage required for operationof heater pad 152 is typically higher than that needed for mirror unit14, different size leads and different type electrical connectors areused for heater pad 152 to avoid misconnection. Alternately, separateapertures through the center mounting plate 100 or retaining plate 110may be provided for leads 153, 154. As shown in FIG. 14, sufficientspace between the inside surface of retaining plate 80, 110 and the rearsurface of mirror unit 14 is provided to allow use of a heater pad 152as described above. If desired, heater pad 152 may be directly adheredto the back of rear element 18 over reflective layer 34 withoutincluding foil sheet 151. In such case, pad 152 is die cut to match theshape of mirror element 18. When operated, the heating pad 152 provideselectrical resistance heating for the rear element 18 which, byconduction, is also carried to front element 16 for defrosting andde-icing purposes on mirrors used in colder climates.

While several forms of the invention have been shown and described,other forms will now be apparent to those skilled in the art. Therefore,it will be understood that the embodiments shown in the drawings anddescribed above are merely for illustrative purposes and are notintended to limit the scope of the invention which is defined by theclaims which follow.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows.
 1. A rearview mirrorassembly for vehicles comprising:a rearview mirror including a mirrorelement having front and rear surfaces and peripheral top, bottom andopposing end edges and a reflective coating on one of said front andrear surfaces; a bezel surrounding and holding said mirror and having arim engaging said front surface of said mirror, a peripheral sideadjacent said peripheral edges of said mirror, and means for holdingsaid mirror within said bezel; and mounting means for connection to amirror support; said bezel rim including a crown extending around theentire bezel and an inner edge engaging said front of said mirror, saidcrown being spaced inwardly toward said inner edge from said peripheralside and dividing said rim into an inner surface sloping from said crownto said inner edge and a lateral surface sloping from said crown towardsaid peripheral side of said bezel whereby when viewed from said frontof said mirror at an angle, said bezel appears thinner than its fullwidth due to light accenting said crown and deemphasizing said inner rimsurface.
 2. The mirror assembly of claim 1 wherein the projection ofsaid inner surface has a length greater than the length of theprojection of said lateral surface.
 3. The mirror assembly of claim 2wherein said crown is formed by a relatively sharp edge between saidinner surface and said lateral surface along each of said peripheralopposing end edges of said mirror, said crown having a more roundedconfiguration along said peripheral top and bottom edges of said mirror.4. The mirror assembly of claim 2 wherein the ratio of said length ofsaid inner surface projection to said length of said lateral surfaceprojection is greater along said peripheral opposing side edges of saidmirror than along said peripheral top and bottom edges.
 5. The mirrorassembly of claim 1 wherein said bezel rim has a recessed undersurfaceforming a channel extending around said rim, said channel adapted toreceive a seal material for providing an environmental seal around theperipheral edges of said mirror when said bezel receives said mirror. 6.The mirror assembly of claim 5 wherein said inner edge of said bezel rimincludes a generally planar undersurface engaging said front surface ofsaid mirror.
 7. The mirror assembly of claim 1 wherein said innersurface is substantially planar.
 8. The mirror assembly of claim 7wherein said lateral surface is substantially planar.
 9. The mirrorassembly of claim 1 wherein said inner edge of said bezel rim includes agenerally planar undersurface engaging said front surface of saidmirror.
 10. The mirror assembly of claim 1 wherein said lateral surfaceis substantially planar.
 11. The mirror assembly of claim 1 wherein saidcrown is formed by a sharp edge between said inner surface and saidlateral surface along each of said peripheral opposing end edges of saidmirror, said crown having a more rounded configuration along saidperipheral top and bottom edges of said mirror.
 12. A rearview mirrorassembly for vehicles comprising:a rearview mirror including a mirrorelement having front and rear surfaces and peripheral top, bottom andopposing end edges and a reflective coating on one of said front andrear surfaces; a bezel surrounding and holding said mirror and having arim engaging said front surface of said mirror, a peripheral sideadjacent said peripheral edges of said mirror, and means for holdingsaid mirror within said bezel; and mounting means for connection to amirror support; said bezel rim having a first width along said frontmirror surface adjacent said top and bottom edges, the width of saidbezel rim along said opposing end edges being less than said first widthwhereby when viewed at an angle from the front and adjacent one end,said bezel appears smaller at said end edges of said mirror therebydeemphasizing the size and appearance of said bezel on said assembly.13. A rearview mirror assembly for vehicles comprising:a rearview mirrorincluding a mirror element having front and rear surfaces and peripheraltop, bottom and opposing end edges and a reflective coating on one ofsaid front and rear surfaces; a bezel surrounding and holding saidmirror and having a rim engaging said front surface of said mirror, aperipheral side adjacent said peripheral edges of said mirror, and meansfor holding said mirror within said bezel; and mounting means forconnection to a mirror support; said bezel rim having a first widthalong said front mirror surface adjacent said top and bottom edges, thewidth of said bezel rim along said opposing end edges being less thansaid first width whereby when viewed at an angle from the front andadjacent one end, said bezel appears smaller at said end edges of saidmirror thereby deemphasizing the size and appearance of said bezel onsaid assembly; said bezel rim including a crown extending around theentire bezel and an inner edge engaging said front of said mirror, saidcrown being spaced inwardly toward said inner edge from said peripheralside and dividing said rim into an inner surface sloping from said crownto said inner edge and a lateral surface sloping from said crown towardsaid peripheral side of said bezel whereby when viewed from said frontof said mirror at an angle, said bezel appears thinner than its fullwidth due to light accenting said crown and deemphasizing said inner rimsurface.
 14. The mirror assembly of claim 13 wherein the projection ofsaid inner surface has a length greater than the length of theprojection of said lateral surface.
 15. The mirror assembly of claim 13wherein said bezel rim includes an undersurface which is recessedforming a channel extending around said rim, said channel adapted toreceive a seal material for providing an environmental seal around theperipheral edges of said mirror when said bezel receives said mirror.16. The mirror assembly of claim 13 wherein said inner edge of saidbezel rim includes a generally planar undersurface engaging said frontsurface of said mirror.
 17. The mirror assembly of claim 13 wherein saidinner surface is substantially planar.
 18. The mirror assembly of claim17 wherein said lateral surface is substantially planar.
 19. A rearviewmirror assembly, especially for use on the exterior of a vehicle,comprising:a rearview mirror having front, rear and peripheral edgesurfaces and including a mirror element having a reflective coatingthereon; a bezel surrounding said mirror and having a rim engaging saidfront surface of said mirror and an imperforate peripheral side adjacentsaid peripheral edge surface of said mirror; said rim having anundersurface facing said mirror; a retaining member adjacent said rearsurface of said mirror and engaging said bezel for holding said mirrorwithin said bezel, said retaining member having an inner surface facingsaid mirror; cooperating means on said bezel and retaining member forholding said retaining member and bezel together; mounting means forconnection to a mirror support; and seal means within said bezel andretaining member for sealing said peripheral edge surface of saidmirror, said seal means including a first resilient compressible sealmember extending around the entirety of said mirror adjacent said mirrorperipheral edge surface and intermediate said rim undersurface and saidmirror front surface and a second resilient compressible seal memberextending around the entirety of said mirror adjacent said mirrorperipheral edge surface and intermediate said retaining member innersurface and said mirror rear surface, said seal members and the innersurface of said peripheral side of said bezel defining a generally openpocket adjacent said peripheral edge surface of said mirror around saidmirror, said pocket being sealed environmentally to protector saidperipheral edge surface including the peripheral edge of said reflectivecoating against environmental conditions and effects such as dirt,water, salt spray, humidity and corrosion, said first seal memberresiliently urging said mirror rearwardly against said second sealmember and retaining member to ensure a secure environmental seal and tohold said mirror tightly and cushion said mirror against vibration andshock.
 20. The mirror assembly of claim 19 wherein said mirror is anelectro-optic mirror unit having at least one transparent panel, anelectro-optic material adjacent said panel, electrical means forapplying electrical power to said electro-optic material to vary thelight transmittance of said material, and a reflective layer forreflecting light incident thereon through said material.
 21. The mirrorassembly of claim 20 wherein said electro-optic material is anelectrochromic medium.
 22. The mirror assembly of claim 20 wherein saidelectrical means include electrical connections secured to the peripheryof said mirror unit within said pocket; said seal members protectingsaid electrical connections against corrosion, shorting and otherenvironmental effects.
 23. The mirror assembly of claim 19 wherein atleast said first seal member is formed from a seal material which issubstantially cured to a non-tacky, non-adhesive state prior to assemblywith said mirror whereby said mirror may be disassembled from said bezelfor removal or re-adjustment of position without adherence of said firstseal member to said mirror.
 24. The mirror assembly of claim 23 whereinsaid undersurface of said bezel rim is recessed thereby forming achannel extending around said rim, said channel receiving said firstseal member, said first seal member being applied within said channeland projecting out of said channel for contact with said mirror frontsurface prior to assembly of said bezel with said mirror.
 25. The mirrorassembly of claim 19 wherein said retaining member is a plate having aperipheral edge; said cooperating means including spaced shoulders onsaid bezel peripheral side and a ramp surface leading to each of saidshoulders; said peripheral edge of said plate adapted to engage saidramp surfaces and resiliently urge said bezel peripheral side outwardlyso as to snap behind said shoulders against said second seal member onsaid mirror rear surface when pressed toward said mirror duringassembly; said bezel peripheral side being sufficiently resilient toflex outwardly when said ramp surfaces are engaged by said peripheraledge of said plate.
 26. The mirror assembly of claim 25 wherein saidplate includes a rear surface;said assembly including connecting meansfor electrical connections to said mirror on said rear surface of saidplate.
 27. The mirror assembly of claim 26 wherein said plate includesan opening therethrough, said opening having an edge; said mountingmeans including a second plate having connections to a mirror supportjoined to said edge of said opening through said plate.
 28. The mirrorassembly of claim 26 wherein said mounting means includes a second platehaving connections to a mirror support joined to said plate.
 29. Themirror assembly of claim 25 including heating means on said rear surfaceof said mirror intermediate said plate member and said mirror.
 30. Themirror assembly of claim 19 including heating means on said rear surfaceof said mirror intermediate said retaining member and said mirror.
 31. Arearview mirror assembly for vehicles comprising:an electro-optic mirrorunit having front, rear and peripheral edge surfaces and including atleast one optically clear panel, an electro-optic material adjacent saidpanel, electrical means for applying electrical power to saidelectro-optic material to vary the light transmittance of said material,and a reflective layer for reflecting light incident thereon throughsaid material, said mirror unit also including a pair of electricalconnections to said electrical means; a bezel surrounding and holdingsaid mirror unit and having a rim engaging said front surface of saidmirror unit, a peripheral side adjacent said peripheral edge surface ofsaid mirror unit, and means for holding said mirror unit within saidbezel; and mounting means for connection to a mirror support; said bezelincluding a support for mounting said pair of electrical connections forconnection to a vehicle electrical system; said pair of electricalconnections having opposite polarities and mounted on said support andincluding means for preventing incorrect polarity connections to thevehicle electrical system.
 32. The mirror assembly of claim 31 whereinsaid means for holding said mirror unit within said bezel include aretaining member adjacent said rear mirror surface and spaced shouldermeans on said bezel for holding said retaining member on said bezel,said retaining member including apertures therethrough allowing passageof said electrical connections from said electrical means.
 33. Themirror assembly of claim 32 wherein said retaining member includes saidsupport for mounting said pair of electrical connections.
 34. The mirrorassembly of claim 31 wherein said means for preventing incorrectpolarity connections to the vehicle electrical system include said pairof electrical connections being mounted to extend in differentdirections on said support, each connection adapted to mate with anelectrical connection of the same polarity on a electrical lead having alength preventing attachment to said differently directed, oppositepolarity, electrical connection on said support.
 35. The mirror assemblyof claim 31 wherein said means for preventing incorrect polarityconnections to the vehicle electrical system include said pair ofelectrical connections each having a different size/dimension adapted tomate with a correspondingly sized connection of the same polarity fromthe vehicle electrical system.